Folded Carton Shipping Frame for Floral Stability
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Solution Overview
Problem
Existing packaging solutions for flowers and similar products are inefficient in reducing plastic usage and carbon footprint, as they often rely on heavier and more costly plastic materials, and lack effective stabilization during handling and transport.
Innovation Solution
A shipping assembly using a frame made of folded corrugated or hard board carton materials, with ergonomic handles and inner strapping options, which reduces plastic usage, weight, and carbon footprint while enhancing stability and pack rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic materials are used for frames, then strength and stability are improved, but weight and cost increase
Solution Approach 1:
The patent changes the material parameter from plastic to corrugated carton, transforming the physical properties of the frame material to achieve lighter weight while maintaining structural integrity through the corrugated structure's inherent strength-to-weight ratio
Solution Approach 2:
The patent uses composite construction by combining corrugated carton material with strategic reinforcement elements, creating a hybrid structure that leverages the lightweight properties of carton while adding minimal reinforcement where needed to maintain frame strength
2Reliability
If plastic materials are used for frames, then durability is improved, but environmental impact and cost increase
Solution Approach 1:
The patent adopts disposable corrugated carton frames that can be easily discarded after use, replacing durable but non-biodegradable plastic frames. The carton material is designed to be sufficiently durable for single-use shipping applications while being environmentally benign and recyclable
Solution Approach 2:
The patent enables recovery and recycling of the carton material after use, transforming the linear plastic waste model into a circular economy approach where the packaging material can be discarded responsibly and recovered for reuse, eliminating plastic pollution
3Ease of manufacture
If standard carton boxes are used, then cost is reduced, but pack rate and stability deteriorate
Solution Approach 1:
The patent segments the packaging system into modular frame units made from standardized carton components, allowing efficient assembly and optimized space utilization that increases pack rate compared to traditional monolithic box designs
Solution Approach 2:
The patent transitions from two-dimensional flat carton boxes to three-dimensional framed structures, utilizing vertical and lateral dimensions more effectively to create stable configurations that maximize packing efficiency and product stability
4Strength
If plastic frames are used, then structural integrity is improved, but ease of disposal deteriorates
Solution Approach 1:
The patent designs the frame as a disposable component made from corrugated carton that provides sufficient structural integrity for its intended shipping lifecycle, then can be easily discarded or recycled without special handling requirements, unlike plastic frames that require specialized disposal procedures
Data Source
AI summary
A shipping assembly includes a folded core, made of corrugated carton or other foldable material, formed with a hollow center along the entirety or a portion of the core. A base at a bottom of the folded core is foldable along a folding line to attain a perpendicular position to the folded core. The base has two protrusions above the folding line. Upper and lower lateral members include two folded tabs which are inserted in upper and lower portions, respectively, of the column assembly to form a frame assembly. The frame assembly is affixed to an inner volume of a box.